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irregularities)
Gas pores and porosity
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Cracks
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Cracks
Cracks that may occur in welded materials are caused generally by many factors and may be classified by shape and position, cracks are classed as planar.
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Process Cracks Hydrogen induced cold cracking (HICC) Solidification cracking (Hot Tearing) Lamellar tearing Re heat cracking
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Cracks
Lamellar tearing
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Transverse crack
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Longitudinal crack
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Inclusions
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Gas Cavities
Gas pore <1.5mm Blow hole.>1.6mm
Gas pore Cluster porosity
Arc length too large Damaged electrode flux Moisture on parent material
Root piping
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Gas Cavities
Porosity
Root piping
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Cluster porosity
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Herringbone porosity
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Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion caused by some welding process
Slag originates from welding flux MAG and TIG welding process produce silica inclusions Slag is caused by inadequate cleaning Other inclusions include tungsten and copper inclusions from the TIG and MAG welding process
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Slag inclusions
Lack of Fusion
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Lack of Fusion
Poor welder skill Incorrect electrode
manipulation
Arc blow Incorrect welding
1 2
current/voltage
Incorrect travel speed
Overlap
An imperfection at the toe or root of a weld caused by metal flowing on to the surface of the parent metal without fusing to it
Contamination Slow travel speed Incorrect welding technique Current too low
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Overlap
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Incomplete filled groove Poor cap profiles and excessive cap reinforcements may lead to stress concentration points at the weld toes and will also contribute to overall poor toe blend
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Poor stop/starts
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Miscellaneous Defects
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Miscellaneous Defects
Spatter
Excessive current Damp electrodes Contamination Incorrect wire feed speed
Miscellaneous Defects
Accidental striking of the arc
Arc strike
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Cap Undercut
Root undercut
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Cap undercut
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Shrinkage groove
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Concave root
Excessive root bead grinding before the application of the second pass
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Concave Root
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Concave root
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Burn through
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purging gas
Most commonly occurs
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Crater Pipe
Weld crater
Crater pipe
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Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it has the appearance of a gas pore in the weld crater
Contamination
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Mechanical Damage
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Mechanical Damage
Mechanical damage can be defined as any surface material damage cause during the manufacturing process. This can included damage caused by:
Grinding Hammering Chiselling Chipping Breaking off welded attachments (torn surfaces) Using needle guns to compress weld capping runs
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Mechanical Damage
Chipping Marks
SetSet-up Irregularities
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Note: Unequal leg lengths on a fillet weld may be specified as part of the design, in which case it will not be considered as a defect.
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SetSet-up Irregularities
Linear misalignment is measured from the lowest plate to the highest point. Plate/pipe Linear Misalignment (Hi-Lo)
SetSet-up Irregularities
Linear Misalignment
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SetSet-up Irregularities
Linear Misalignment
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Any Questions
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Questions
Weld Defects
QU 1. Give two main causes for the occurrence of a burn through QU 2. Give two main causes for the occurrence of excessive root penetration on a single-V butt weld QU 3. Give five defects, which may occur when welding carbon steel using the MMA welding process with the current setting to low QU 4. Give three possible causes for the occurrence of lack of side wall fusion QU 5. Sketch the following defects a. Lack of root wall fusion b. Lack of root penetration c. Incomplete filled groove d. Concave root
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Material Inspection
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Material Inspection
All materials arriving on site should be inspected for:
Material Inspection
Parent material defects include:
Mechanical damage Lamination Lap
Segregation line
Laminations are caused in the parent plate by the steel making process, originating from ingot casting defects. Segregation bands occur in the centre of the plate and are low melting point impurities such as sulphur and phosphorous. Laps are caused during rolling when overlapping metal does not fuse to the base material.
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Material Inspection
Plate Lamination
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Weld Repairs
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Weld Repairs
A weld repair may be used to improve weld profiles or
the inspector must ensure that the defects have been totally removed and the original joint profile has been maintained as close as possible
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Weld Repairs
The specification or procedure will govern how the defective areas are to be removed. The method of removal may be
Any Questions
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